Wireless conveyor belt condition monitoring system and related apparatus and method

Abstract

A method includes transmitting first wireless signals towards a conveyor belt having multiple layers of material. The first wireless signals penetrate one or more layers in the conveyor belt. The method also includes receiving second wireless signals that have interacted with the conveyor belt. The method further includes identifying a condition of the conveyor belt using the second wireless signals and outputting an indicator identifying the condition of the conveyor belt. Identifying the condition of the conveyor belt could include identifying a thickness of at least one of the layers in the conveyor belt. This could be done by identifying pulses in the second wireless signals and using time of flight calculations.

What is claimed is: 
     
       1. A method comprising:
 transmitting first wireless signals towards a conveyor belt comprising multiple layers of material, the first wireless signals penetrating and reflecting off more than one layer in the conveyor belt; 
 receiving second wireless signals that have interacted with the conveyor belt; 
 identifying a condition of the conveyor belt using the second wireless signals; and 
 outputting an indicator identifying the condition of the conveyor belt. 
 
     
     
       2. The method of  claim 1 , wherein identifying the condition of the conveyor belt comprises:
 identifying a thickness of at least one of the layers in the conveyor belt; and 
 determining that the conveyor belt is worn when the thickness of the at least one layer is below a threshold. 
 
     
     
       3. The method of  claim 2 , wherein identifying the thickness of the at least one layer comprises:
 identifying pulses in the second wireless signals that have reflected off different surfaces of the at least one layer; and 
 using time of flight calculations with the identified pulses to determine the thickness of the at least one layer. 
 
     
     
       4. The method of  claim 3 , wherein using the time of flight calculations comprises:
 using a deconvolution algorithm to identify the second wireless signals that are strongest path signals; 
 determining times of flight using the pulses in the strongest path signals; and 
 using a time difference between the times of flight to determine the thickness of the at least one layer. 
 
     
     
       5. The method of  claim 1 , wherein identifying the condition of the conveyor belt comprises:
 determining whether pulses in the second wireless signals are indicative of an exposed reinforcing structure or one or more defective belt joints. 
 
     
     
       6. The method of  claim 1 , wherein:
 transmitting the first wireless signals comprises transmitting first wireless signals at each of upper and lower covers of the conveyor belt; 
 receiving the second wireless signals comprises receiving second wireless signals from each cover of the conveyor belt; and 
 identifying the condition of the conveyor belt comprises identifying the condition of the upper and lower covers of the conveyor belt. 
 
     
     
       7. The method of  claim 1 , wherein identifying the condition of the conveyor belt occurs when the conveyor belt is loaded with material, when the conveyor belt is unloaded, and when the conveyor belt moves around a mean position. 
     
     
       8. A system comprising:
 a transmitter configured to generate first wireless signals for communication towards a conveyor belt via at least one antenna so that the first wireless signals penetrate one or more layers in the conveyor belt; 
 a receiver configured to receive via the at least one antenna second wireless signals that have interacted with the conveyor belt; and 
 a signal processing unit configured to identify a condition of the conveyor belt using the second wireless signals; 
 wherein the transmitter is configured to transmit the first wireless signals at each of upper and lower covers of the conveyor belt; 
 wherein the receiver is configured to receive the second wireless signals from each cover of the conveyor belt; and 
 wherein the signal processing unit is configured to identify a condition of the upper cover and a condition of the lower cover of the conveyor belt. 
 
     
     
       9. The system of  claim 8 , wherein the transmitter and the receiver form a transceiver. 
     
     
       10. The system of  claim 8 , wherein the signal processing unit is configured to identify the condition of the conveyor belt by:
 identifying a thickness of at least one of the layers in the conveyor belt; and 
 determining that the conveyor belt is worn when the thickness of the at least one layer is below a threshold. 
 
     
     
       11. The system of  claim 10 , wherein the signal processing unit is configured to identify the thickness of the at least one layer by:
 identifying pulses in the second wireless signals that have reflected off different surfaces of the at least one layer; and 
 using time of flight calculations with the identified pulses to determine the thickness of the at least one layer. 
 
     
     
       12. The system of  claim 11 , wherein the signal processing unit is configured to use the time of flight calculations by:
 using a deconvolution algorithm to identify the second wireless signals that are strongest path signals; 
 determining times of flight using the pulses in the strongest path signals; and 
 using a time difference between the times of flight to determine the thickness of the at least one layer. 
 
     
     
       13. The system of  claim 8 , wherein the signal processing unit is configured to identify the condition of the conveyor belt by:
 determining whether pulses in the second wireless signals are indicative of an exposed reinforcing structure or one or more defective belt joints. 
 
     
     
       14. The system of  claim 8 , wherein the transmitter is configured to generate first wireless signals that penetrate and reflect off more than one layer in the conveyor belt. 
     
     
       15. An apparatus comprising:
 at least one interface configured to receive wireless signals that have interacted with a conveyor belt; and 
 at least one processing device configured to identify a condition of the conveyor belt using the wireless signals; 
 wherein the at least one processing device is configured to identify the condition of the conveyor belt by determining whether pulses in the wireless signals are indicative of an exposed reinforcing structure or one or more defective belt joints. 
 
     
     
       16. The apparatus of  claim 15 , wherein the at least one processing device is configured to identify the condition of the conveyor belt by:
 identifying a thickness of at least one of the layers in the conveyor belt; and 
 determining that the conveyor belt is worn when the thickness of the at least one layer is below a threshold. 
 
     
     
       17. The apparatus of  claim 16 , wherein the at least one processing device is configured to identify the thickness of the at least one layer by:
 identifying pulses in the wireless signals that have reflected off different surfaces of the at least one layer; and 
 using time of flight calculations with the identified pulses to determine the thickness of the at least one layer. 
 
     
     
       18. The apparatus of  claim 17 , wherein the at least one processing device is configured to use the time of flight calculations by:
 using a deconvolution algorithm to identify the wireless signals that are strongest path signals; 
 determining times of flight using the pulses in the strongest path signals; and 
 using a time difference between the times of flight to determine the thickness of the at least one layer. 
 
     
     
       19. The apparatus of  claim 15 , wherein the at least one interface is configured to receive wireless signals that have penetrated and reflected off more than one layer in the conveyor belt. 
     
     
       20. The apparatus of  claim 15 , wherein the at least one processing device is configured to identify the condition of the conveyor belt when the conveyor belt is loaded with material, when the conveyor belt is unloaded, and when the conveyor belt moves around a mean position.